Method of making one-piece hollow doorknobs



' Sept. 7, 1954 F. w. LwERMoN-rl ET AL 2,688,297

METHOD OF MAKING ONEPIECE HOLLOW DOORKNOBS 8 Sheets-Sheet l Filed May 16, 1949 a Lf Sept. 7, 1954 Fjw. LlvERMoNT ET AL 2,688,297

\ METHOD oF MAKING ONE-PIECE HoLLow DooRKNoBs Filed May 1e. 1949 s sheets-sheet 2 Sept. 7, 1954 F. w. Llvl-:RMoNT ET AL 2,688,297

METHOD OF MAKING ONE-PIECE HOLLOW DOORKNOBS Filed May 16. 1949 8 Sheets-Sheet 3 IN VEN TORS Sept. 7, 1954 F. w. Llvl-:RMoNT ET Al. 2,688,297

METHOD oF MAKING ONE-PIECE HOLLOW DooRKNoBs Filed May 16. 1949 a sheetssheet 4 BY 7i/Wy@ Sept. 7, 1954 F. w. I lvERMoNT ET AL 2,633,297

METHOD OF MAKING ONEPIECE HOLLOW DORKNOBSY Filed May 16, 1949 8 Sheets-Sheet 5 6??.19.- be .b9 |07 Y arme/Veys Sept. 7, 1954 F. w..| |vERMoNT ET A| 2,688,297

METHOD OF MAKING ONE-PIECE HOLLOW DOORKNOBS Filed May 16. 1949 8 Sheets-Sheet 6 Sept. 7, 1954 F. w. LlvERMoNT ET AL 2,588,297

METHOD OF MAKING ONE-PIECE HOLLOW DOORKNOBS 8 Sheets-Sheet '7 Filed May 16. 1949 mm MJ. lm L m f f ...m Q xlflixlw ,`..l.|| v O VE; G Q/ Aw f W. R WOT 85 8 c.. A m m f INVENTORS BY'/.r

Sept. 7, 1954 F. w. LIVERMONT ET AL 2,688,297

METHOD oF MAKING oNE-P1EcE HoLLow DooRKNoBs Filed May 16. 1949 8 Sheets-Sheet 8 s1 no o 3. Sw 3 mm Q/ l Y si???I "Inu: l

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Bf Qi@ Patented Sept. 7, 1954 UNITED STATES PATENT OFFICE METHOD OF MAKING ONE-PIECE HOLLOW DOORKNOBS fornia Application May 16, 1949, Serial No. 93,524

7 Claims.

This invention relates to the art of metal stamping and processing, and is particularly directed to a method and apparatus of forming a bulbous part such as, for example, a door knob, and is also directed to a new and improved form of door knob construction.

It is an object of our invention to provide a method and apparatus adaptable to quantity production techniques for manufacture of hollow bulbous door knobs or the like from a continuous at strip of material.

A more detailed object is to provide a new and improved method and apparatus for manufacture of a bulbous part using conventional punch presses.

Another object is to provide a method and apparatus for expanding a bulb-shaped stamping into a one-piece door knob or the like by employing hydraulic pressure within the stamping, the expansion becoming complete substantially simultaneously with the closing of the die.

Another object is to provide a new and improved method and apparatus for accurately sizing the interior or the neck of the bulb-shaped stamping prior to the operation of expansion under a hydraulic pressure in order that the hydraulic plunger may accurately nt the interior of the neck portion.

Other and more detailed objects and advantages will appear hereinafter.

In the drawings:

Figures 1 to 11 illustrate diagrammatically the sequence of steps we employ in forming a onepiece door knob from a flat sheet of material. Thus, the iiat sheet shown in Figure 1 is drawn to form a cup in Figure 2, and this cupy is deepcned in the steps shown in Figures 3 and 4. The flange on the cup shown in Figure 4 is removed to produce the cup shown in Figure 5, and an annealing operation normally takes place after the formation of the cup shown in Figure 5. The annealed cup of the shape Shown in Figure 5 is then necked down in conventional dies in sequence as shown in Figures 6, 7, 8 and 9. The bulb-shaped stamping shown in Figure 9 is then processed in accordance with our invention to produce the bulbous part shown in Figure 10 which has a smooth ironed bore of accurate size within the neck portion. The part shown in Figure 10 is then expanded hydraulically in accordance with our invention to produce the finished door knob shown in Figure 11.

Figures 12 to 18 illustrate the method and apparatus for forming the part shown in Figure l0 from the part shown in Figure 9. Figure l2 is a sectional view showing a preferred form of apparatus for simultaneously reducing the neck portion of the bulbous part and for ironing the internal diameter of the neck, the parts being shown at the beginning of the operative stroke of the press. Figure 13 is a viewy similar to Figure 12 with the parts shown in position corresponding to movement of the press platen partway through its stroke. Figure 14 is a fragmental sectional elevation showing the action of the mandrel in ironing the internal bore of the neck of the bulbous part. Figure 15 is a view similar to Figure 13 showing the position of the parts corresponding to the end of the operative stroke of the press platen. Figure 16 is a sectional elevation partly broken away taken substantially on the lines lli-I6 as shown in Figure l2. Figures l' and 18 are transverse sectional views taken substantially on the lines I'l-I'l and IB--IS respectively as shown in Figure 13.

Figures 19 to 27 relate to the method and apparatus for hydraulically expanding the bulbous part shown in Figure l0 to produce the completedrdoor knob shown in Figure 11. Figure 19 is an elevation partly in section showing parts in initial position before the movement of the press platen commences. Figure 20 is a sectional detail partly broken away showing the action of the hydraulic plunger in expanding the bulbous part before the die set reaches closed position. Figure 21 is a sectional view on an enlarged scale showing the die set in closed position and showing the construction of the hydraulic plunger. Figure 22 is a view similar to Figure 21 illustrating the iinal position of the parts corresponding to the end of the stroke of the press platen. Figures 23 and 24 are sectional elevations illustrating the action of the lock means employed for locking the upper and lower halves of the die set together against separation by the hydraulic pressure. Figure 23 Shows the position of the locking parts corresponding to the position of the die set shown in Figure 20. and Figure 24 shows the parts in locked position corresponding to the position of the die set shown in Figures 21 and 22. Figure 25 is a plan View looking upwardly as shown by the lines 25-25 in Figure 19, partly in section and showing the parts of the locking mechanism. Figure 26 is a sectional view partly broken away taken substantially on the lines 26-26 as shown in Figure 24. Figure 27 is a sectional plan View partly broken away taken substantially on the lines 21-21 as shown in Figure 21.

Figures 28 and 29 are sectional views showing a modied form of apparatus for the hydraulic expansion of the bulbous part.

Figure 30 is a sectional plan view partly broken away taken substantially on the lines 23S-35 as shown in Figure 29.

Referring to the drawings, the die set and associated parts shown in Figures 12-18 are used in making the bulbous part Ii) shown in Figure from the necked cup 9 shown in Figure 9. The ve operations for producing the parts shown in each of Figures 6-10 are preferably performed'in sequence in a dial feed press. In addition, a preoiling operation and an extracting, operation may be performed in the same press. Thepart. 9 is placed upright within the lower die II. soithat the necked portion extends upwardlyin, axial alignment with the punch I 2 and with the upper die I3. The lower die II is retained by means of a die holder It secured to an axially'immovable base or nxed platen I5. A plunger I6 is slidably mounted within a bore I'I in the xed platen I5 so that the lower die II may move relativerto the fixed platen I5 under certain conditions described below. The upper die I3 is provided with a flared central opening I8 at its lower end which joins a cylindrical-bore I9 which extends axially through the die I3. The die holder 25 is connected to the die I3 by means of threaded elements 2l and a die holder sleeve 22 encircles lthe die i3 and the die holder 20. The die holder 2U is anchored with respect to the moving platen 23 by means of threaded elements 24, The upper portion of the die holder 29 is provided with a transverse axially extendingslot 25 which receives the sliding crosshead .25 whichcarries the punch l2. A pair of stop rods 2l is fixed at the ends of the crosshead 2E and extends downwardly on opposite sides of the die holder sleeve and is arranged to contact the upper surface of the lower die holder Ed at one stage in the operative cycle.

A retaining ring 23 is vprovided with aicentral opening shaped to t the contour of the part 9 at the large end of its tapering portion and prevents bulging, This plate is carried onvaplurality of screws 25 slidably mounted within the axially extending recesses 30 formedin the die sleeve 22. are received within other recesses 32 formed in the die sleeve 22 and encircle upstanding pins33 xed on the plate 28. From this description it will be understood that the retaining ringll is nor-. mally moved downwardly by means of the coil,y

springs BI and the limit of its downward movement is fixed by engagement of the heads of the cap screws 2S with shoulders at the lower ends of the recesses Sii. As the die I3 moves downwardly during theoperating cycle the retaining ring 2S rests on the upper end of the lowerr die I I and remains stationary while. the upper die I3` moves downwardly.

As the moving platen 23 moves downwardly under influence of the-moving platen of the punch press (not shown), the retaining ring 28A moves over the upper end of the part 9 and the punch I2 enters the upper open end of the necked portion of the part 9. It will be observed that the largest diameter of the punch I2 is smaller than the I2 and cross-head 253` is arrested at` the instantthat the lower ends of the stop -rods VV21 engage `the A plurality of compression springs .3I.

upper surface of the lower die holder I4. Further downward movement of the platen 23 and die I3 is made possible by the release of latch means generally designated 35 which allows the lower die I i to move downwardly with respect to the axially immovable platen I5. The latch means may include a latching lever 35 pivotally connected at 3"! between a pair of stationary brackets 33. These brackets may be secured to the platen I5 by means ef threaded elements 39.

A roller [l0 mounted on the plunger I5 cooperates with a nose portion 4I on the latching lever so that clockwise movement of the lever as viewed in Figures 12, 13 and 15 serves to permit descent of the plunger IE and lower die I I. A tension spring 42 secured at one end to the lever Sii and at the other end to the pin i3 on bracket 33. serves normally to holdl the latching lever 36 in the position shown in Figure 12. A vertical tripping bar d4 is slidablyA mounted with respect to the platen land is resiliently supported by means of acoilspring flacting on cross-pin 46.

Acap screw i? may be threaded into a recess 43.

provided in the upper platen 23 andheld in adjusted position by means of a lock nut 69. The spring llnormally maintains the upper end of the trip rod lll in contact with the head of the cap screw 4l. rThe lower end 5H of the trip rod Mis adapted to contact the outer end of the latching lever 35 upon descent of the upper platen 23. The position of the cap screw il is adjusted on the platen 23 so that the lower end 5G of the trip rod iii releases the latching lever 3G at the instant that the upper die I3 comes in contact with the relatively stationary retaining. ring 28.

Upon release of the latching device 35 the lower die I I moves downwardly under the force applied bythe upper die -I3 acting through the retaining ring 28. The necking is completed when die I3 contacts ring 28 -further downward movement performs the ironing operation described below. A plurality of parallel pins 5I is slidably mounted in the brackets 3'8, and at their upper ends these pins contact the plunger I6 and at their lower ends rest on an annular plate 52 encircling a stationary bolt 53 carried by the brackets 3S. A compression spring 54 encircles the bolt and is confined between the plate 52 and the nut 55. The function of the spring 54 is to return the plunger I6 and lower die II back to the initial position shown in Figure 12 after completion of the operative cycle.

Itwill be observedin Figure 13 that the upper die I3 acts to reduce the diameter of the neck of the part Sto such an extent that the inner diameter of the neck is smaller than the diameter of the cylindrical surface 56 on the punch I2. Accordingly, when the latch mechanism 35 is re leased to allow the lower die II to move downwardly with respect to the platen I5, the bulbous part Si is carried downwardly with respect to the punch. I2. In other words, the relative movement between the descending part 9 and the stationary punch I2'. is such that the cylindrical surface 56 reduces the wall thickness of the neck of the part 9 in an.ironing opera-tion. Thus. the necking diev I3. moves the part S downwardly, stripping it over the enlarged portion of the punch I2 while confining the outer diameterof the neck'. The result is that a vsmooth cylindricalv dense surface Elisproduced on the inner diameter of the neckof the part 9, and this-surface 51 is exceptionally uniform and accurate in diameter. FigureV 14 shows the ironing process when lpartly completed, and Figure 15 shows the posi '5 tion of the parts upon completion of the ironing.

The punch I2 is provided with a segmental expansion ring 58 which may comprise a plurality of ring segments 59 mounted within a groove 60 formed on the punch I2 below the location of the cylindrical surface l. A dished washer 6I acts as a spring and urges the retaining ring 62 to move upwardly so that the ring segments 59 are caused to move radially outwardly by the conical surface 63 formed on the punch I2. The hub 54 may be fastened on the punch I2 by means of a pin 55. The segmental expansion ring 58 has a maximum diameter which will pass into the open end of the part 9 when it is initially inserted in the lower die I I. However, when the upper or necking die I3 further contracts the neck of the part 9 around the punch I2 as shown in Figure 13, the contracted inner diameter of the neck of the part 9 is smaller than the diameter of the cylindrical surface 5l. The ring segments 59 are contracted by contact with the inner wall of the neck of the part 9 and hence the segmental ring 58 oers no resistance during the ironing operation illustrated in Figure 14. When the ironing operation is complete, however, and when the segmental ring 58 moves out of the confinement of the neck of the part 9, the ring segments 59- expand under the influence of the resilient annular washer tl and overlie the upper end 66 of the part 9. This relationship is shown in Figure 15.

When the platen 23 moves upwardly on the return part ci the stroke, the ironing die I3 moves upwardly with the platen and the ironed part now designated Ill sticks in the upper die I3 by reason of the tight t of the neck therein following the ironing operation. As the platen 23 moves upwardly the plunger I@ carries the lower die |I back toward its initial position under the action of the compression spring 54 acting through pins 5|. i

Spring 69 is mounted on the moving platen of the press and by initial compression and through the pin 6l applies a continuously downward force on the crosshead 2S. This is effective to cause ejection of the workpiece at the start oi the upward movement of the platen leaving the workpiece in the lower die I I, from which it is removed at the next station of the dial piece (not shown) The plate 63 may be interposed between the spring G9 and pin 6l and the spring may be enclosed within the shell 19.

This completes the operations on the bulbous part Ill and it is then ready to be expanded hydraulically to form the completed door knob illustrated in Figure 11.

Referring to Figures 19-2'7, the bulbous part II) having the accurately sized cylindrical surface 57 is placed in another die assembly for hydraulic expansion. This die assembly includes a lower die 89 and an upper mating die 8|. A movable plunger 32 extends axially through the central opening in the upper die 9|. This plunger 82 is provided with an accurately sized cylindrical seal ing surface |53 which ts closely within the surface 5l and provides a sealing fit therewith. The lower end of the plunger is reduced in size and provided with wrench flats 81| enabling the plunger to be turned for engaging the threaded connection 85. The threaded connection 35 connects the upper end of the plunger 82 to the bushing 86 slidably mounted within the central bore 'I formed in the upper die holder 36. The bore 81 terminates in an annular shoulder 89. A coaxial bore 99 extends upwardly from the lower part of the die holder 88 and terminates in a shoulder 9|. A coaxial cylindrical bore 92 of reduced diameter connects the shoulders 39 and 9|. A flange 93 on the bushing' is adapted to engage the annular shoulder 89 to arrest downward movement of the bushing and plunger 82. An ejector sleeve 94 encircles the upper portion of the plunger 82 and is provided with a ange 95 at its upper end. This flange is adapted to engage the annular shoulder 9i to limit upward movement of the sleeve 96. A plurality of parallel ejector pins 99 extend axially through the moving platen 96 and die holder 98 and extend through apertures 91 and 98 so that their lower ends rest on the ilange 95 of the sleeve 9A.

The apertures 91 are formed in the bushing mi) which is screwed into a threaded counterbore IIJI formed in the upper portion of the upper die holder 88. An ejector stem |62 extends through a central opening |93 provided in the bushing |99 and extends upwardly into an axial recess |94 provided in the moving platen 96. The upper end of the ejector stern |92 engages an annular shoulder IIJ'I provided at the end of the recess |04. A bumper element |98 is slidably mounted within an axial bore |99 provided in the upper platen 96 and rests on the upper ends of the ejector pins 99. The upper end of the bumper element |08 extends upwardly out of the bore |99 for contact with a stationary bar (not shown).

The lower die 89 is provided with a central cylindrical bore III) and a counterbore III at the lower end thereof. An indenting button II2 is slidably received within the bore IIII and is provided with a iiange portion IIS which fits within the counterbore III. A lower die holder plate I Ill is secured to the lower die 89 by any convenient means (not shown), and this die holder plate is received within a recess H5 provided in the lower or xed platen IIG. An axial stud III threaded into the platen IIE carries a nut |I8 which supports a pair of plates |I9 and 29 having a rubber disk I2! positioned therebetween. Compression pins |22 extend axially through openings provided in the lower platen I I5 so that the lower die holder plate IM rests on the upper end of the pins |22 and so that the lower ends of these pins rest on the plate I I9. The arrangement is such that downward movement of the lower die 89 is permitted by squeezing cf the rubber disk I2I. Such downward movement of the lower die 80 is limited by engagement of the die holder plate IIll with the bottom of the recess ||5.

The button IIZ does not move downwardly with the lower die holder II, but on the contrary is supported on stationary pins |23 which are slidably mounted within the die holder plate II4 and which rest on a stationary insert IEM carried by the lower xed platen IIii.

As shown in Figure 25 the upper die 8| is secured to the die holder 88 by means of clips |136 on opposite sides of the die 8|. These clips engage within an annular groove Isl' formed on the die 8l, and they are secured to the die holder 88 by means of headed cap screws Id which pass through slots |49 in the clips.

Means are provided for releasably locking the moving platen with respect to the stationary platen in order to maintain the dies 99 and 8| in closed position. As shown in the drawings this means includes a series of hook elements |25 which are secured to base pieces |253 by means of anchor pins |21. The base pieces |25 are secured to the lower stationary platen llt by any convenient means such as, for example, the cap "aessgagv screws |28 (see'Figure'ZG). A series of bracket .elements |29 are secured tothe upper die holder 68 by means of lock pins |39. A series of pusher elements |3| are secured to base members |32 `by means of lock pinsk |33, and the base members |32 are in turn secured to themoving platenli by any convenient means such as, for example, the cap screws |34. Briey stated, the series of hook elements |25 `are secured relative tothe lower platen, the series of bracket elements are secured relative to the upper die holderxS, and the series of pusher elements 3| are secured relative to the upper moving platen 23.

The upper die holder 86 is mounted for a relative sliding movement with respect to the upper platen 96. A horizontally extendingrecess v|35 is formed on the underside of theplaten k96 and is .adapted to receive the upper die holder ,83. Guide pins |35 are xed in the platen 95 andare slidably mounted with respect to the upper .die holder 88 to guide the latter in its Vmovement relative to the platen 96. Parallel bolt elements |37 are threaded into the platen S3 and are slidably received within openings |38 provided on the upper die holder B8. Coil springs |35 encircle the elements |31 within the openings |33 and act against an enlargedhead |46 on the lower-end of each of the elements I3?. The upper end of each of the coil springs |39 engages an annular shoulder |4| on the upper die holder. The `ac tion of the springs |39 is to move'the upper die holder B3 upwardly into the recess I 35. This action normally is prevented by locking hars |42 and rollers |43. The bars |42 extend along each series of latching elements |25, |29 and |3|ras shown clearly in Figures 25 and 26. The rollers |43 turn freely on the bars |42, and in theposition shown in Figure 19 actto prevent upward movement of the upper die holder .e3 with respect to the moving platen 95. As shown in Figure 19, the rollers |43 .are interpositioned between horizontal abutments |44 provided on the bracket elements |252 .and horizontal abutments |45 provided on the pusher elements |3|. The locking bars |42 remain in the position shown in Figure 19 until the moving platen 96 and its .associated parts move downwardly a sufficient distance to move the cylindrical portion 83 vof the plunger 82 into the upper end of the bulbo-us work piece I0. At thattime the rollers |53. engage within the curved slots |50 and the rollers |43 and bars |42 are moved outwardly away from the .die holder 88 so that they move out from underfthe shoulders |45 and are in position to enter the slots in the pusher elements |3|.

Lateral movement of the bars |552 and rollers |43 to release the locking action between the Idie holder 88 and the platen 96 is completed at the instant that the upper die 8| reaches closed position with respect to the lower die 3C .as illustrated in Figure 21. Further downward movement .of the platen Sli-'forces the plunger 52 downwardly, but the die holder 88 and upper die v8| remain relatively stationary, with 'the die holder v8E. entering the recess |35 in the platen 55. The curved slots |50 on the hook'elenients |25` cause the rollersv |43` to move under the shoulders |52 on the hook elements so that separation of the dies 80 and 3| under hydraulic pressure within the die cavities is eiectivelyprevented.

From this description it will beunderstood that the function of the locking parts |25,r |29, |3| and |43 is threefold: (a) to .lock the .die holder Bil-with respect to the platen 96 for a portion of the stroke of the platen 95; (b) tov releasethe die'.holder,2881:withlrespectto' thev platen Y96 whenthesupper-diel,and lowerzdie :80 meet in contact; and (c) to lockthe upperplaten '96 with respect tothe lower Aplaten H3 to prevent .separation of the dies '80 and 8| while the hulbous part I 0 is being hydraulically expanded into contact withl .the lclosed diel cavity.

In operation the hulbous work piece I0 is lled with hydraulic iiuid. This uid may be water or waterl with a suitableA additive such as, for example, soap. Upondownward movement of the platen96 the plunger 82 traps a predetermined quantity of 'hydnafulicriuid within the interior of the bulbouspart I0. The form .of hexagonal end-84 of the plunger maybe made just the proper lengthto :trap :the desired quantity of hydraulic iluid ywhen the cylindrical surface 83 of the plunger'enters into sealing vcontact .with the cylindricalbore 51 Ain the neck .ofthe bulbous part Hl. The hydrauiicfluid trapped withinthe` interior of the part |20 ,expands the part under the inluence of pressure developed bythe plunger 82 as it'moves intoishe interiorofthe part l0. The eapansionoperation -begins substantially before theupper `die'l imeetsthe lower die 80. This featurel of-theinvention is illustrated in Figure 20 and constitutes animportant advantage becauseA it enables use of a larger bulbous part I0 in relationtozthe ,-size of the finished Ydoor knob than would be .the case if-the dies were together .before the expansion gbegins, requiring relatively less expansion of the bulb. When the upper and lower dies i8| and 80 meet in metal-to-metal contactfalong their engagement ,surfaces |53, the locating yring |54 on the :upper ,die 8| encircles the cylindrical surface v|55.onxthelower die and its closely therewith.

-As set forthrabove, V,engagement of the `upper and lower idies=s8| :and .Bilxcoincides with release of the lock between the upper die holder B8 and the moving :platen 96. Continued downward movementpf the moving `platen 96 moves the plunger "82 fromthe positionshown in Figure, .21 to the position shown in Figure .22. The pressure developed :within the interior Vof the workpiece expands itinto1tightcontact with the Walls Lof the cavity generallyA designated |56. :Theshape of the top of'thebutton ||2 is therefore impressed intoI the wall of the work piece, and yany corrugations or ',designsare thus faithfullyfreproduced on the work piece. Thefpressure. developed within the A,interior of the work piece is relatively high :and inpractice has been found to be sufficiently great to separate the dies 30 and 8| along the surfaces |53, if no provision is .made to lock the dies1against separation. The `action of the locking rollers |53` movingunder the'projection |52 ron'the hook elements|25 effectively prevents separation .of the dies 8|) andt8| under this relatively high vunit pressure.

We have; found it desirable to employ a spring loaded check valve assembly -withinthe 'interior of the plunger. 82 -in'order to kallow excess hydraulicuidvto escape when the unit vpressure exceeds `a predetermined maximum. As shown in the drawings this check valve assembly ,generally designated .|51 includes a ball |58 engaging. conical seat |59 to close, the openingr |60. A follower|6| restsagainst the ball |58. Aecoil spring |62 is vmounted .within an .axial ,bore |63 in theplungeiw82. One end .of this .spring rests against the follower |6| and the other end contacts thethreaded plug |64 which is positioned withinthe extremeupper end Vof the plunger 82. The plug |64 maybe adjustably positioned kalong the threaded portion |65 of the bore |63 to vary the force exerted by the spring upon the follower IBI. A passage IE6 extends through the follower ISI so that any hydraulic uid passing the ball check enters the bore |63. A central passage IB'I is provided within the adjustable threaded plug |64. This passage communicates with port |68 within the bushing 86. An outlet for hydraulic fluid reaching the port E68 is provided by intersecting axial and radial openings |69 and Il@ respectively positioned within the lower end of the ejector stern |02. Hydraulic fluid passing outwardly through the radial opening |'I0 passes into the bore |83 and outwardly to atmosphere through aligned ports I'II and |12 in the bushing It@ and die holder S8 respectively. The lower die S is held in its upper position, with the indenting button I I 2 in its retracted position to allow the bulb to stretch without dragging the metal across the circumferential indenting edge H23. The rubber disk I2| holds the lower die @Il in its upper position until it is moved downwardly by direct contact with the upper die 8|.

When the moving platen 96 is retracted upwardly the lock bars |22 and lock rollers |43 move radially inwardly under the iniluence of the curved portions |73 on the pusher elements Iii I, thereby moving the rollers M3 out from under the abutments |52 on the hook elements |25. The locking parts are therefore returned to the position. shown in Figure 19. Continued upward movement of the platen 96 separates the dies 8b and El. The finished part then has the shape of the door knob shown in Figure 11. This part remains in the upper die ill and moves upwardly therewith by reason of the relatively tight nt within the upper portions of the die cavity. When the moving platen 96 approaches the upper end of its stroke a stationary bar (not shown) strikes the upper end of the bumper elemnt |00 and arrests its upward movement. This in turn stops the upward movement of the ejector pins se and the ejector sleeve 94. Since the lower end of the ejector sleeve 94 bears against the upper end of the completed door knob, the latter is stripped from the upper die 8l as it continues in. its upward movement. A new bulbous blank Iii is iilled with hydraulic fluid and placed in position and the cycle repeats.

The finished part as shown in Figure l1 has a cylindrical neck IS@ provided with the smooth, accurate cylindrical bore 5l. The surface of the metal or the 1core lil is dense and smooth and round by reason of the processing operations above described. The metal thickness of the curved belled portion IBI is thicker than that of the neck Iil and of the fully expanded bulb portion li because the intermediate belled'portion It! has been subjected neither to the ironing operation nor to the maximum expansion by hydraulic pressure. There are no machine marks on the interior or the exterior of the neck because no machining operations are employed, and accordingly there are no regions of high stress concentration in the area where the intermediate belled portion i8! joins the neck |80. The length of the neck |00 may be trimmed as desired or it may be left exactly as it comes from the belled portion IBI is particularly advantageous because it is in this region that the highest stresses occur during the service life of the door knob. These stresses tend to concentrate in this belled portion IBI by reason of the twisting effort applied to the door knob, as well as to lateral forces occasioned by rough usage.

Referring to the modied form or our invention shown in Figures 28 to 30, the upper and lower dies 260 and 20| cooperate when closed to form a cavity of the desired shape. A bulbous part I0 as shown in Figure 10 of the drawings is placed on the lower die and filled with hydraulic fluid. The part is then hydraulically expanded to the shape of the die cavity in the manner outlined above. This embodiment of our invention, however, does not employ lock means for preventing separation of the upper and lower diesv and the rubber ring is mounted on the upper die assembly instead of the lower one.. As shown in Figure 28 the lower die 20| may be bolted directly to the fixed platen 202 by means of the cap screws 203 and hold-down ring 204. The upper die 200 is fixed to die holder 205 by means of cap screws 206 and ring 201. An annular rubber disk 200 is confined between the holder 205 and the plate 209 by means of threaded elements 2|0. These threaded elements extend through aligned openings in the plate 209 and rubber disk 208 and are threaded at 2II into the upper die holder 205. The plunger 2|2 may be constructed substantially the same as that previously described and is encircled by the ejector sleeve 2 I3. Parallel ejector pins 2 Ill rest on the flange at the upper end of the ejectorsleeve 2 I3 and at their upper ends engage a flange 2|5 on the lower end of the ejector stem 2|6. The plunger 2|2 is fixed relative to the upper platen 2I'I by means of a xed plate 2I8. A check valve assembly 2|9 of substantially the same type previously described may be provided within the plunger 2I2.

In operation the plunger 2 I2 enters the cylindrical bore 51 within the bulbous blank l0 and hydraulic expansion of the part begins before the dies 200 and 20| meet in metal-to-metal relationship. In other words, the expansion begins before the die cavity is closed. The expanding part fills the die cavity at substantially the time that the upper and lower dies 200 and 20| meet in contact. Continued downward movement ofA the platen 2|'I moves the plunger 2|?! further downwardly into the interior of the expanded part, causing it to conform accurately to the shape of the walls of the die cavity. This additional movement of the plunger 2I2 after the tinues its upward movement. The finished part is thereby stripped from the upper die 206i. A new bulbous blank I0 may then be inserted and filled with hydraulic fluid for repetition of the cycle.

Having fully described our invention, it is to be understood that we do not wish to be limited 1-1` to the details herein set forth, but our invention is ofthe full scope ofthe appended claims.

We claim:

1. The method of forming a door knob from a necked cup having an expandable bulbous portion, comprising: ironing the inside surface of the neck of the cup while the outside surface thereof is confined against lateral expansion to produce a smooth cylindrical inside surface of uniformdiameter and final predetermined size, introducing liquid` into said' necked cup for use in hydraulically expanding the bulbous portion thereof, utilizing the interior surface of the neck portion as a means for effecting a seal with a pressure applying member to confine the liquid in`th'e cup, applying pressure to said liquid while supporting at least a portion of the exterior of said neck against deformation to thereby start theexpansion of the bulbous'portion and simultaneously With and during further expansion of said/bulbousl portion, applying external pressure tore'shape the exterior of the expanded bulbous portionto thev final desired shape.

2. The method of forming a door knob from a" blank comprising a single integral shell having a large expandable bulbous part including an elongated substantially'cylindrical side wall and a' bottom wall, a relatively small coaxial cylindrical neck, and an intermediate flaring portion integrally joining the lower end of the cylindrical neck and the upper end of the cylindrical side Wall of the bulbous portion, the neck being of substantially uniform diameter from the upper end of said flaring portionl to its outermost extremit'y and having smooth cylindrical interior andy exterior surfaces of final nished size, comprising: providing a predetermined volume of liquid in said blank at least suiiicient to hydraulically expand the bulbous portion of the blank tothe shape desired, utilizing the interior surface of the finished neck portion as a means for effecting a seal With a pressure applying plunger of predetermined diameter, while supporting the neck portion against lateral expansion to thus confine said liquid in said blank, applying pressure to the liquid by moving said plunger into s'aid blank to start expansion of` said bulbous portiomand after partial expansion of said bulb ous portion and simultaneously with and during further' expansion of said bulbous portion, applying' external pressure to reshape' the exterior of the expanded bulbous portion to the final desired shape.

3. The method of forming a door knob from a blank comprising a single integral shell having a large expandable bulbous part including an elongated substantially cylindrical side wall and a bottom wall, a relatively small coaxial cylindrical neck, and anintermediate i'iaring portion integrally joining the lower end of the cylindrical neck and the upper end of the cylindrical side Wall of the bulbous portion, the neck being of substantially uniform diameter from the upper end of said iiaring portion to its outermost extremlty and having a smooth cylindrical interior and exterior surface of filial finished size, comprising: supporting the blank upon a first die member having a die cavity, introducing liquid into said blank forv use in hydraulically expanding the bulbous portion thereof, simultaneously moving a second die member having a die cavity, and a plunger, into engagement with said blank, utilizing the interior surface of the finished neck portion as ameans for effecting a seal with said plunger while supporting the outer surface of said neck'by said second die member to' prevent lateral expansion thereof, moving said second die member and plunger towardithe first die member to effect initial expansion of thel bulbous portion of the blank while the die members are still spaced apart, and continuing the movement of said die members toward each other during further expansion of said bulbous portion to apply pressure to reshape'the exterior of the expanded bulbous portion to a final desired shape determined by said die cavities.

4. The method of expanding a blank having a single integral shell including a small cylindrical neck, and a coaxial relatively large expandable bulbous portion provided with an elongated substantially cylindrical side Wall, a bottom wall, and a flared portion integrally joining the cylindrical neck and tlie upper end of the cylindricalside wall of said bulbous portion, the neck being hard and dense and having smooth cylindrical inside and outside surfaces of final predetermined size, the side and bottom walls of the bulbous portion being relatively soft and in a stress-relieved state, comprising the steps of: positioning said blank between open diev parts; providing a metered amount of liquid in said blank at least sufficient in volume to hydraulically expand the bulbous portion of said blank to the shape desired; starting closing of the die parts while applying pressure to said liquid by a plunger of predetermined diameter slidably extending through said neck; utilizing the smooth inside surface of said neck to form a' seal with said plunger and supporting the smooth outside surface of said neck against enlargement to thus confine said liquid to start expansion of said bulbous portion; and simultaneously with and during the further expansion ofv said bulbous portion, continuing to completion the closing of said die parts to apply external pressure to said expanded bulbous portion to reshape the exterior thereof to a filial desired shapeconforming to said die parts.

5. The method of expanding a blank having a single integral shell including a small cylindrical neck, and a coaxial relatively large expandable bulbous portion provide with an elongated substantially cyindrical side wall, a bottom y wall, and a fiared portion integrally joining the cylindrical neck and the upper end of the cylindrical side wall of said bulbous portion, the neck being hard and dense and having smooth cylindrical inside and outside surfaces of iinal predetermined size, the side and bottom walls of m the bulbous portion being relatively soft and in a stress-relieved state, comprising the steps of: positioning said blank between open die parts; substantially completely filling the blank with liquid, displacing a portion of the liquid from said blank by introducing a plunger, of a predetermined diameter and having a reduced end of predetermined volume, into the neck of said blank to leave a relatively predetermined amount of liquid in said blank at least sufficient in volurne to expand the bulbous portion of said blank to the shape desired; starting closing of the die parts while applying pressure to said liquid by said plunger; utilizing the smooth inside surface of said neck to form a seal with said plunger and supporting the smooth outside surface of said neck against enlargement to thus confine said liquid to start expansion of said bulbous portion; andsimultaneously with and during the further expansion of said bulbous portion, continuing to completion the closing of said die parts to apply external pressure to said expanded bulbous portion to reshape the exterior thereof to final desired shape conforming to said die parts.

6. The method of expanding a blank having a single integral shell including a small cylindrical neck, and a coaxial relatively large expandable bulbous portion provided with an elongated substantially cylindrical side Wall, a bottom wall, and a iiared portion integrally joining the cylindrical neck and the upper end of the cylindrical side wall of said bulbous portion, the neck being hard and dense and having smooth cylindrical inside and outside surfaces of final predetermined size, the side and bottom walls of the bulbous portion being relatively soft and in a stress-relieved state, comprising the steps of: providing a metered amount of liquid in said blank at least sufficient in volume to expand the bulbous portion of said blank to the shape desired; contacting a close fitting plunger with the inside surface of said neck to form a seal therewith and supporting the outside surface of said neck against enlargement to thereby confine the liquid in said bulbous portion, and moving said plunger inwardly while said bulbous portion is unconned to apply pressure to said liquid in said blank to start expanding said bulbous portion to thereby increase the volumetric content thereof, and then die-shaping the exterior of the bulbous portion by closing a die cavity thereabout to confine and shape said bulbous portion while continuing the expansion thereof, whereby to limit the shape of said bulbous portion to a predetermined maximum size and shape conforming to said die cavity.

7. The method of expanding a blank having a single integral shell including a small cylindrical neck, and a coaxial relatively large expandable bulbous portion provided with an elongated substantially cylindrical side wall, a bottom wall, and a ared portion integrally joining the cylindrical neck and the upper end of the cylindrical side Wall of said bulbous portion, the neck being hard and dense and having a smooth cylindrical outside surface and an ironed inner surface of final predetermined size, the side and bottom walls of the bulbous portion being relatively soft and in a stress-relieved state, comprising the steps of: providing a metered amount of liquid in said blank at least sufficient in volume to expand the bulbous portion of said the Industrial Press, pp. 843-351.

14 f blank to the shape desired; connlng said outer surface of said neck against enlargement; contacting a close fitting plunger with the ironed inner surface of said neck to form a seal therewith to thereby confine the liquid in said bulbous portion, and moving said plunger inwardly to apply pressure to said liquid in said blank to start expansion of said bulbous portion to increase the volumetric content thereof, and then die-shaping the exterior of the bulbous portion by closing a die cavity thereabout to confine and shape said bulbous portion to limit it to a predetermined maximum size and shape while continuing movement of said plunger to expand said bulbous portion.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 126,610 Wood May 7, 1872 222,251 Dackus Dec. 2, 1879 748,404 Munro Dec. 29, 1903 788,119 Pope Apr. 25, 1905 795,020 Barthelmes July 18, 1905 1,503,023 Carlson July 29, 1924 1,766,098 Booth June 24, 1930 2,006,691 Giesler July 2, 1935 2,129,120 Davis Sept. 6, 1935 2,128,614 Kobayashi Aug. 30, 1938 2,133,199 Wendel Nov. 29, 1938 2,157,044 Wendel May 2, 1939 2,233,212 Cornell Apr. 15, 1941 2,284,773 Sivian et al. June 2, 1942 2,312,749 Bullock Mar. 2, 1943 2,354,005 Flowers July 18, 1944 2,407,855 Stephens Sept. 17, 1946 2,493,053 Zatyko Jan. 3, 1950 2,582,358 Schoellerrnan Jan. 15, 1952 2,592,867 Cuq Apr. 15, 1952 FOREIGN PATENTS Number Country Date 4,494 France June 14, 1906 OTHER REFERENCES The book Die Design and Die Making Practice, edited by F. D. Jones, 2nd ed., published by (Copy in Div. 14.) 

